Mortar cement



Patented Apr. 18, 1933 UNITED STATES ALLIIIII PATENT OFFICE ORIE E. WASSON, OF YOUNGSTOWN, OHIO, ASSIGNOR TO THE BESSEIVIEB CEMENT COR- PORATION, OF YOUNGSTOWN, OHIO, A CORPORATION OF OHIO MORTAR CEMENT No Drawing.

This invention relates to a cement composition having hydraulic properties, and more particularly to a mortar cement containing as essential ingredients slag, cement clinker and shale.

I have discovered that raw shale may be included in a slag cement composition with beneficial results and without destroying the hydraulic characteristics of the mixture if certain conditions are followed. I prefer to employ a shale because of its definitely lower water ratio in comparison with clays, etc., and to grind the total mix to a fineness exceeding 95% passing through a 200 mesh screen, and to take into account other considerations as hereinafter described. I further contemplate the use of a foaming agent to promote light workability when used in sanded mortar, and raw gypsum to control the setting time, all as hereinafter described.

I have succeeded in producing a cementitious composition having slow-setting, high early and long time strength hydraulic properties together with plasticity and light workability in sanded mortar; the mixture having stability in its dry form and the capability of use over an extended period of time in its wet form without disagreeable lumping and stiffening from flash set. The comparative cost of manufacture is low and permits the utilization of inexpensive raw materials.

In the prior art, cementitious materials containing slag are well known. In many of these so called prior slag cements, the slag has been used as an aggregate and was not ground to the fineness of an impalpable flour, so that it was not intended to take advantage of the inherent hydraulic properties of such slag. In other proposals of the prior art where slag and cement have been finely ground for hydraulic purposes, it has been considered necessary to mix therewith a material such as lime to give it workability. The lime has been disadvantageous for the reason that it interfered with the strength and hydraulic capacity and its high water absorbing power or normal consistency ratio permits the mortar mix to freeze easily in cold weather. It has also been proposed Application filed January 21, 1931. Serial No. 510,319.

to anneal slag prior to its incorporation in a slag cement, upon the fallacious theory that the reactivity is thereby affected. Experience has proved that the reactivity of slag is determined by its composition and granular size or fineness. I have found that basic slag, when ground fine, is rapidly reactive with calcium hydroxide of certain origin. When hydrolysis of cement takes place, calcium hydroxide is liberated and unites with the feebly basic constituent slag to form more basic compounds. The mono-calcium silicate of the slags, adds on calcium oxide from the calcium hydroxide liberated from the cement, to form di-calcium silicate, which is recognized as a cementitious compound giving long time strength. Thus the finely ground Portland cement, yielding calcium hydroxide in water solution upon hydrolysis, thereby avoiding the high water ratio necessary with the introduction of free extraneous lime, acts as an energizer to induce rapid development of improved hydraulic properties in the slag. The problem has been to utilize the vast quantities of furnace slag available and its desirable potential hydraulic properties in masonry and to overcome its highly disadvantageous nonplastic characteristics.

I have found that sla and Portland cement will react to produce compositlons 1av1ng desirable propertiesof strength, but that such compositions do not have the plasticity necessary for commercial and successful use. This is probably due to the dense glassy structure of slag which, while porous, prohibits any absorption of intergranular water films; the sharp hard edges of the slag particles increase the internal frictional resistance when manipulated in water admixture in mortar preparation.

It is well known, of course, that plasticity of Portland cement can be increased b fine grinding, but the problem of flash set is encountered Very quickly. Fine grinding of a slag Portland cement mix, also increases plasticity and also unduly quickens the setting time so that flash setting will result.

It has been proposed to increase the plas- 100 ticity of wall plasters and the like by using therein a mixture of clay or shale together with limes and waxy constituents. However, free lime, on account of its high normal consistency or water absorption ratio is detrimental to the cement strength development. Shales and clays have been considered undesirable additions that hinder the set hardening and development of strength of the resultant mixture in use. Shale has been defined as a consolidated laminated clay. For the most part, the prior art has indicated the use of shales and clays as a gregates or fillers. The number of species 0 clays are multitudinous, and the art has in most instances disregarded the characteristics which define clays from one another.

I have found that by using a definite type of raw lastic shale of low normal consistency or wa er re 10 and finely grinding the slag-cement mixture with which it is incorporated that we obviate the disadvantages of the prior art. I have discovered that I can include shale of this type in a slagcement composition, and contrary to what has commonly been supposed, maintain high strength in the composition together with easy workability, or plasticity. In other words it is possible to secure a highly plastic condition in an admixture of low water ratio constituents if the grinding is fine enough and the particular constituents are properly balanced, one against the other. Thus strength can be maintained together with plasticity. This discovery is primarily based upon the use of shale of a definite type and finely grinding the entire slag and cement clinker mixture containing this shale; it will be understood, however, that variations of the type of slag and cement clinker will necessitate slight changes in conditions. Prior art and field experience continuously reveals the general notion that plasticity increase must be at the sacrifice of strength in cements and vice versa.

I have discovered that all clays and corresponding shales will not act alike in the operation of my invention. I have found that the maintenance of high strength together with plasticity is dependent upon the use of a plastic argillaceous substance with a definite water ratio. For example, an argillaceous substance having a water ratio of 15 to 1 (that is, 100 grams of it will require 1500 grams of water to wet it up to a paste) will not give high strength in the final product. Such substances with very high water ratios are of the bentonite type. Highly plastic clay like ball, paper, and china clays usually have water ratlos from 1 to 1 up to 2.5 or 3 to 1. Even these lowered water ratios preclude the addition of suificient clay to produce a satisfactory plasticity and still maintain a satisfactory strength. Again, there are oil shales and practice of my invention, I use a raw lastic clay or shale that, when round, has a water ratio substantially less than I to l, and grind the slag-cement-shale mixture to a fineness such that at least 95% of tlfi same will pass through a 200 mesh screen. 1 also incorporate with the mixture of slag, ce-

ment clinker and shale, a as entrainin or foaming a ent to give light workability to t e mass w en used in sanded mortar.

For this ingredient, I prefer to use Eank water or other organic wastage suc lue. blood or animal refuse. It is well nown to use organic retarders to delay the setting time of calcined gypsum plasters and the like. However, organic material is here used for a different purpose than as a retarder. It is used for efi'ectin a li ht workin ortar mixture which has a wealth 0 minute air bubbles. T'llS incorporatlon of orgamc agent, and the subsequent entrainment of minute air bubbles as the sanded mortar is made, decreases the weight of the mortar, and the air bubbles reduce the internal friction when the harsh, sharp particles of the wet mortar slide over one another. This is highly desirable from the standpoint of the mason, as a heavy, short mortar is difficult to use successfully.

The organic tankage is added in sufiicient amount to maintain entrained air bubbles only during the time the wet mortar is being worked and placed, consequently the bubbles break rapidl and expel the air, which substantially disappears before the time of setting commences, so that the resultant structure is back to its normal density and is non-porous. Thus by the use of air-entrainment the necessity for having a mortar of high water content to promote fluid working is obviated. Air is a fluid, but not permanent in the mortar mass, hence strength of the cementitious ingredients is not sacrificed in any way to gain workability in the mortar, as would be the case if a permanent high fluid ratio from water alone, was used.

It is my belief that fine grinding and aeration not only promote the plasticity of the mixture by increasing surface areas and thus filming areas, but also have a special eflect on the shale with respect to the reaction and setting of slag and cement. I believe that fine grinding of the shale causes it to form a solid solution with the reaction product of slag and cement, and thus not 106. COMPOSITIONS, Exam};

COATING OR PLASTIC.

only give up water for the hydration reresulting mixture of slag, cement, shale, gypaction, but to take part in the actual resum, and foaming agent:

action itself, secondarily forming a solid solution. This theory accounts in part for the unexpected high strength obtained in the product when shale of definite water ratio is used accompanied by the aforesaid fine grinding.

Another component of the preferred finixture is sum. Raw sum is use to regulatfkmng timi s is understood Ignltlon g g z gg ii zfi i fi m im mved Physical characteristics, when tested by P y p the methods prescribed by the American Somortar cement is as follows: Per cent ciety for Testing Materials for Portland Ce- 80 Slag 1 ment, are as follows:

Portland cement clinker 27 .0 i i set 2 hrs. 30 min.

Hard blue Shale Final set 5 hrs. 10 min,

Raw gyp soundness. OK 2 Organic foaming agent 3 85 TENsILE STRENGTH-13 STANDARD Mommas This mixture is round preferably to a fineness of 98% passing through a 200 mesh sieve.

lhe slag is a Water anulated basic w Zdays y Ydays 8 m 3 w. 6mo. 90

high calcium blast furnace sla with the 16111 0 ving average anally sis: 106 150 22a 328 414 512 565 Pounds per sq. in.

Percent Si0 50 COMRESSIVE SmNorn-1-3 STANDARD Mommas F6203 u A1 0 11 4 Pounds per sq. in. 95

C210 46 87 MgO 2.72 day 2days 3days 7days 28days 3mo. 6mo. Sulphur 1 12 7 1 1243 a MnO 1.32 6 6 1 3058 468a 5624 6110 100 The Prnd 0961' has the While I have indicated the specific details lowing yp Per cent and analyses of the materials which go to Sio 21 02 make up the preferred embodiment, it is to 2 n b distinctl understood that I do not desire 40 FeOO 3. 56 e y 105 to be limited thereto exce t as indicated A1 0 6. 8O 7 P m 0&0 i 67. 03 fP f 2 MgO 1. 20 c 1. A mortar cement having hydraulic The blue Shale has t e followmg yp characteristics comprising a mixture of basic analysis: slag, cement clinker, and shale ground to a no SO gg 'g fineness of more than 95% passing through 1 2 a 200 mesh screen, the ingredients being in 2 3 73 such proportions as to give a troweling 2 63 plasticity in cement mixtures without using free lime, 115 gO- 2. A new manufacture comprising a pul- Alkahes 80 verized mixture of a fineness exceeding Comblned Water 20 95% passing through a 200 mesh screen The yp has e l i t i l containing a substantially cellular slag hav- 120 l i ing slow setting hydraulic characteristics, a

Per cent substantially amorphous tricalciuni silicate 2 having rapid setting hydraulic character- Kings istics, and a substantially laminated alumi- Cab a 31 94 nurn Sll1Cate hflV1I1g water-plastic charac- 12;

M00 r2 teristics, the ingredients being in such pro- 3 -3 portions as to give a trowel ng plasticity Combined Water u 20. 95 in cement mixtures without using free lime.

I 3. A cement mixture ground to a fineness The following is a typical analysis of the exceeding passing through a 200 mesh 1 0 screen comprising non-plastic slag material capable of reacting with cement clinker to form dicalcium silicate, cement clinker, and a plastic shale having a water ratio lying below the water ratio of china clays, paper clays, ball clays and the like, the ingredients being in such proportions as to give a troweling plasticity in cement mixtures without using free lime.

4. A finely ground hydraulic cement mixture comprising slag, Portland cement clinker and shale, the slag being sufficiently fine to be reactive with water, the cement clinker being sufiiciently fine to possess high early strength characteristics, and the shale having a water-ratio sufficient to permit the slag and cement clinker to react properly when in use, the ingredients being in such proportions as to give a troweling plasticity in cement mixtures without using free lime.

5. A finely ground hydraulic cement mixture having slow setting high early and long time strength characteristics comprising non-plastic slag in predominant amount, Portland cement clinker in lesser amount than slag, and shale in lesser amount than cement clinker, the amount of shale being sufficient to render the mass plastic without disturbing the hydraulic or strength characteristics of the mixture, the ingredients being in such proportions as to give a troweling plasticity in cement mixtures without using free lime.

6. A hydraulic mortar cement comprising a cellular nonplastic slag in predominant amount, Portland cement clinker, and a lamellar plasticizing shale sufiicient in amount to give the mixture workability when mixed with water and to serve as a reservoir for the proper development of hydraulic characteristics, the ingredients being in such proportions as to give a troweling plasticity in cement mixtures without using free lime.

7. A cement mixture having hydraulic characteristics consisting of slag, Portland cement clinker, shale, gypsum and a foaming agent suflicient in amount to give light workability in use, the ingredients being in such proportions as to give a troweling plasticity in cement mixtures without using free lime.

8. A hydraulic cement comprising slag, cement clinker, shale and gypsum ground to a fineness exceeding 95% passing through a 200 mesh screen, the ingredients being in such proportions as to give a troweling plasticity in cement mixtures without using free lime.

9. A hydraulic cement comprising slag, cement clinker, shale, gypsum, and a foaming agent, all ground to a fineness exceeding 95% passing through a 200 mesh screen, the ingredients being in such proportions as to give a troweling plasticity in cement m1xtures Without using free lime.

10. A hydraulic cement comprising slag, cement clinker, shale, and a foaming agent, all ground to a fineness exceeding 95% passing through a 200 mesh screen, the ingredients being in such proportions as to give a troweling plasticity in cement mixtures without using free lime.

11. A mortar cement comprising a finely ground mixture of cellular slag substance having hydraulic properties and capable of developing long-time strength, hydraulic cement capable of developin early strength, and a clayey plasticizing su bstance having a low coeflicient of shrinkage and capable of holding sufficient water adequate for the formation of hydraulic compounds with the hydraulic components, the ingredients being in such proportions as to give a troweling plasticity in cement mixtures without using free lime.

12. A mortar cement comprising a finely ground mixture of porous slag substance having hydraulic properties and capable of developing long-time strength, hydraulic cement capable of developing high early strength, and a clay having a low coefficient of shrinkage and a water ratio below 1 to 1, the ingredients being in such proportions as to give a troweling plasticity in cement mixtures without using free lime.

13. As a new product, a mortar cement comprising slag, cement and shale having a one-day tensile strength of over 100 lbs. per square inch and a 3 month tensile strength of over 500 lbs. per square inch, the ingredients being in such proportions as to give a troweling plasticity in cement mixtures without using free lime.

14. A motar cement comprising slag, cement and shale having a one-day compressive strength of over 700 lbs. per square inch and a 3 months compressive strength of over 5000 lbs. per square inch, the ingredients being in such proportions as to give a troweling plasticity in cement mixtures without using free lime.

15. A new product comprising a mortar cement containing slag, cement and shale having a one-day tensile strength of over 100 lbs. per square inch and a one-day compressive strength of over 700 lbs. per square inch, the ingredients being in such proportions as to give a troweling plasticity in cement mixtures without using free lime.

16. The process of making a mortar cement having high early and long-time strengths and plastic workability which comprises grinding a mixture of slag, cement clinker, and shale to a fineness such that at least 95% will pass through a 200 mesh sieve.

17. A slag mortar cement comprising granulated basis slag, Portland cement clinker, and hydrous shale, the ingredients being in such proportions as to give a trowel- 106. COMPOSITIONS, COATING OR PLASTIC.

lime.

In testimony whereof I have hereunto set my hand.

ORIE E. WASSON. 

